Crafting a Legacy in the NOIRLab Instrument Shop
How one machinist discovered his skills and passion for instrument-making
27 Sept. 2024
Located inside the NSF NOIRLab Headquarters building in Tucson, Arizona, the Instrument Shop serves as an invaluable resource to the function and performance of the organization’s world-class telescopes. From the construction of the KPNO 2.1-meter telescope in the early 1960s to the ongoing construction of NSF–DOE Vera C. Rubin Observatory in Chile, a team of uniquely skilled machinists have been hard at work behind the scenes expertly crafting crucial components for the telescopes and their infrastructure.
The NOIRLab Instrument Shop comprises 650-square-meters (7000-square-feet) of floor space and houses 29 assorted machines, some of which have been in use since the shop first began operations in the 1960s.
Over the years many instrument makers have left their mark on NOIRLab, their craftsmanship crystallized in the physical structures that make up its global network of facilities. And Ron Harris, Instrument Shop Facility Supervisor, has been present in one way or another for over 50 of those years. From walking amongst the bustle of the shop as a young boy to leading a crew of his own, Ron looks at the Instrument Shop with fondness, realizing that he’s been a part of its legacy as much as it's been a part of his.
“As a little dude it was really kind of enchanting. I remember watching all the guys working on these massive machines. Percy Faith’s “Theme From a Summer Place” was playing in the background. I was with my dad, checking out all this cool stuff. It’s a memory that has really stuck with me.”
Before Ron was born, his dad, Bob Harris, owned a local engineering business in Tucson. In the early 1960s he did contract engineering and design work for the newly established Kitt Peak National Observatory (KPNO) where development was picking up after the Association of Universities for Research in Astronomy (AURA) signed a lease with the Tohono O’odham Nation for land on I’oligam Du’ag (Kitt Peak), the highest peak in the Quinlan Mountains. In 1965 Bob and his crew joined AURA to work exclusively with Kitt Peak. By this time the Instrument Shop was fully up and running, producing a multitude of drawings for ongoing projects at KPNO, including the construction of the Nicholas U. Mayall 4-meter telescope (first light 1973) and the building of the Coudé Feed spectrograph for the KPNO 2.1-meter telescope (first light 1964).
As a kid Ron enjoyed listening to his dad talk about all the exciting work being done at NOIRLab (NOAO until 2019). So in 1990 when the Instrument Shop had an opening for an apprentice, Ron jumped at the opportunity. He joined the crew under the supervision of Roger Repp, a tool and die maker by trade who served as Instrument Shop Facility Supervisor from 1985 to 2017. “Roger took a chance on me,” says Ron. “I had the mechanical aptitude, but I didn't know diddly squat about machining or instrument-making.”
This type of expertise is a must for designing and building custom parts for NOIRLab’s state-of-the-art telescopes.
Machining is a kind of manufacturing process that involves removing material, usually metal, from a larger piece of raw material to achieve a desired shape or part. Telescope instrument-making is an even more specialized trade in which the craftsperson needs to know how to, among many things, handle and mount optical components, work with cryogenics, and design and build instrumentation that can perform with the highest levels of precision and accuracy. This type of expertise is a must for designing and building custom parts for NOIRLab’s state-of-the-art telescopes.
For several years Ron worked as an apprentice under the tutelage of Roger, honing his machining skills and finding great pleasure in the work. “It was just this absolute comfort and joy to come into work every day. And I’m thankful to Roger for taking that time to train me because I learned so much,” he says.
In his early years Ron did a lot of work for KPNO. For the WIYN 3.5-meter telescope (first light 1994), he helped build the mirror cell and primary mirror actuators and installed the intricate plumbing for the mirror cooling system — a job that required him to “work upside down like a bat.” He also worked on the Mayall telescope, helping retrofit the dome with air vents and performing upgrades to the telescope’s secondary camera. And he completed work on the auxiliary camera for the McMath-Pierce Solar Telescope, recalling that the coolest moment of that project was meeting the eponym himself, Keith Pierce.
Over the next two decades Ron would contribute to projects across all of NOIRLab’s Programs. During this time the size of the shop crew fluctuated, along with funding and volume of work, until eventually it was just Ron and Roger. So in 2017 when Roger decided to retire, deciding who would take over as Supervisor was a no-brainer.
Luckily, Ron wouldn’t be on his own. He also had Tony Tache, who joined the crew in 2016 as a machinist apprentice. Prior to joining, Tony worked in AURA Logistics. While delivering packages to the shop, he was intrigued by the large machines and intricate work they were carrying out. He expressed interest in learning the trade so Ron took him under his wing. But two machinists wouldn’t cut it, so Ron reached out to an instrument maker whose craftsmanship had caught his eye in the past. In 2017 Anthony Borstad, working for an independent third party, was assisting with upgrades on the Rubin Auxiliary Telescope. His beautifully crafted parts impressed Ron, so when he found himself in a staffing crisis in 2018 he invited Anthony to join the crew.
With his team of Tonys, as he calls them, assembled, Ron felt prepared for the upcoming increase in workload as construction continued on Vera C. Rubin Observatory, being built on Cerro Pachón in Chile with the goal of answering some of astronomy’s biggest questions about the Universe. A brand-new facility meant the need for all kinds of custom parts, and they met the challenge head-on.
For the past seven years the small but mighty crew has demonstrated immense productivity. They have contributed to vital projects for the twin International Gemini Observatory telescopes, the Mid-Scale Observatories at KPNO, and countless Rubin-related projects, some of which include the combined primary/tertiary mirror support system, the secondary mirror light baffle, and the Rubin Commissioning Camera filter system and support structure.
To continue to meet demands and increase productivity, the shop is kept up to date with modern machines and technology. For example, an advanced, seven-axis 3D Coordinate Measuring Machine (CMM, pictured in main image) was recently purchased. Using laser technology, the CMM can take high-accuracy measurements of complex and uniquely-shaped parts and map them into a computer software program. This capability can be used to instantly verify the part dimensions against design dimensions and to reverse-engineer parts for which drawings are not available. Equipment such as this improves the team’s efficiency by allowing them to perform complex quality control dimensional checks in a matter of minutes. It also helps them build their craft by learning new methods and skills.
The diversity of work keeps me interested and passionate.
When asked what his favorite part of his job is, Ron says it’s a combination of the work and people. “Every day I’m met with unique puzzles that need solving and parts that need configuring,” he says. “The diversity of work keeps me interested and passionate.” He also praises his talented team of instrument makers for making the work so enjoyable. But most of all, Ron loves sharing the exciting work that the Instrument Shop is doing with others, whether that be his NOIRLab colleagues or members of the public.
See the NOIRLab Instrument Shop for yourself by booking a free tour of the NOIRLab Headquarters building in Tucson, Arizona, taking place on the first Friday of every month.
